Life-sized origami-inspired Lexus

The replica of the new Lexus IS saloon has been crafted from 1,700 fully recyclable laser-cut cardboard sheets and took three months to build.

Created by a five-strong team of professional designers and modellers from specialist companies LaserCut Works and Scales and Models, and supported by cardboard manufacturer DS Smith, it’s a “celebration of the human craftsmanship skills that go into every car Lexus makes”.

The “origami car” has a fully fitted interior, functioning doors, headlights and rolling wheels – and thanks to an electric motor mounted on its steel and aluminium frame – it can even be driven.

Lexus provided the team with a digital 3D model of the IS, which was then divided into a series of principal parts, such as the main body, dashboard, seats and wheels.

These were then digitally rendered in 10mm “slices” to provide the two-dimensional profiles needed for the laser cutting of each of the 1,700 sheets of 10mm-thick of cardboard – supplied by packaging experts DS Smith.

Each layer was given its own reference number to help ensure it was assembled in the right sequence and the entire assembly was done by hand. A water-based/wood glue was used, which had to be left to set for 10 minutes after each application. Accuracy was vital, as changes couldn’t be made once the glue had dried.

The unique vehicle will be revealed to the public as a star attraction at the Grand Designs Live Show at the NEC in Birmingham (October 8-11).

About Gareth Herincx

Gareth is a versatile journalist, copywriter and digital editor who's worked across the media in newspapers, magazines, TV, teletext, radio and online. After long stints at the BBC, GMTV and ITV, he now specialises in motoring.